Method of and apparatus for sheeting linoleum or the like



M. s. MCCONOUGHEY 1,763,314

June 10, 1930.

METHOD OF AND APPARATUS FOR SHEETING LINOLEUM OR THE LIKE Filed June 22,1927 iii : INVENTOR N m Mel-lg Jijyrlonoufl @51 MATTORNEY Patented June10, 1930 UNITED STATES PATENT .IOFFICE MERLE S. MOCONOUGHEY, OFLLANERCH, PENNSYLVANIA, ASSIGNOR TO CONGOLEUM- NAIRN, INC., ACORPORATIONOF NEW YORK METHOD OF AND APPARATUS FOR SHEETI NG LINOLEUM ORTHE LIKE Application filed June 22',

My present invention relates more particularly to the manufacture oflinoleum floor coverings from plastic compositions of different colors,which are charged into a hopper in gravity feed relation to sheetingrolls whereb they are drawn in, elongated and consoli ated to produce asheet of inlaid linoleum which is variegated in accordance with thecoloring of the plastic compositions. In such primary sheet, the colorpatches are much too elongated, and my invention includes overlappingand cross-rolling the primary sheet, preferably soas to. widen the colorpatches in something like the same ratio that they were lengthened bythe original sheeting operation.

In such a product, the ultimate details of the color pattern arenecessarily and desirably somewhat haphazard,but by proper. selection ofsizes, proportions, and plasticities for the compositions, 'thevariations can be controlled sufficiently to ensure continuousproduction of any desired standard type of patterns, notwithstanding theinfinite variation in its details.

While the standard types or patternsproduced in this way may be'variedwithin wide limits, my method is particularly adapted for the productionof patterns which are substantially devoid of any grain or striatedformation and in which the several colors are sharply defined, therebysimulating the appearance of natural marble. To this end,

the rolls for cross rolling the piles, are preferably rotated atapproximately the same peripheral speed so that the color areas arewidened and consolidated without smearing, of the surface such as islikely to occur where the rolls are run at different speeds.

In most cases it will also be found desirable, for similar reasons (torotate the primary sheet rolls at approxinn'itely the same peripheralspeed. It will be understood, however, that the primary rolls operatingon the cooler, less dense material from the hopper, have less tendencyto heat and smear than do the secondary rolls that operate on the pilesof sheets which have already been subjected to one consolidatingoperation.

I have discovered that the heating etl'ect 1927. Serial No. 200,614.

in the second pair of rolls for cross rolling the \prefer'to usemixtures of standard stiffness which do develop considerable heat. Forthe latter mixtures, and preferably for all mixtures, I have discoveredthat the clearnes's of the marble effects producible by my method can begreatly improved by chilling one of the rolls, preferably by meansadapted to maintain a temperature near or below normal atmospherictemperature, that is, degrees to 60 degrees Fahrenheit, or below.

While the above features of my invention are applicable to formation ofseparate sheets, an important feature of my invention is cutting oil"the primary sheet in suit-- able lengths, overlapping the individualsheetslaterally so as to afford at least four thicknesses of overlapmaterial, maintaining a continuous supply of such overlapped sheets, andpassing the continuous pile of overlapped sheets to the second pairofrolls, for the purpose and with the result of forming a continuousmarbleized sheet adapted for employment in the well known block in- .laymachine of the Walton or Batten type.

Preferably each individual sheet is folded along its margin axls, priorto-pilingsuch sheets in overlapping relation, and-the folded edge ofeach succeeding sheet is positioned to overlay the preceding sheet.These features of folding and positioning are of considerable importaneefor I have discovered that if the individual sheets are presented withfree edges toward the cross rolling rolls. there is likely to be avisible joint or discontinuity in the pattern of the resultingcontinuous sheet, 7

and this may be avoided by folding and presenting the folded edge towardthe rolls.

Heretofore. attempts have been made to produce, from vari-eoloredplastic material. a continuous sheet having a decoration which wouldsimulate natural marble. These attempts consisted in general in mixinglumps of differently colored material and consolidating such lum s bypressure by means of a pair of calen er rolls. The sheets produced,however, failed to give the appearance of natural marble, since theypossess a regularstriated or.grained effect which is foreign to thecharacteristic appearance of marble. Similarly, the use of finelydivided or granular material is well known, to produce a plastic sheethaving a clouded or granite appearance which may or may not be free fromgrained or striated formation, but this product does not in any wayresemble natural marble since the colors are blended so intimately asnot to admit any well defined color areas.

I will now describe, by means of a very specific example, one mode ofcarrying out the preferred form of my particularly to the production ofa continuous sheet of linoleum composition, although it is understoodthat other plastic materials,

which have the same general characteristics of linoleum composition, maybe used in carrying out my method. Likewlse, the apparatus hereindescribed or referred to is being used for illustration only, and myinvention is not to be construed to be limited thereby.

In the accompanying drawings Fig. 1 is a diagrammatic plan view of anapparatus by means of which my invention may be carried out;

Fig. 2 is a diagrammatic elevation of the apparatus shown in Fig 1;

Fig. 3'is a sectional elevation taken on the line 33 of Fig. 2; and

Fig. 4 is a detailed view of the cooling jacket hereinafter referred to.

In these drawings, the hopper 1 is continuously supplied with theplastic linoleum composition 2, preferably in the form of lumps orsausages. Preferably, each lump or sausage is of substantially uniformcolor, the variegations being due to employing a mixture of two or morekinds of .the differently colored lumps. The mixture may compriseparticles of any shape down to average pea size or larger, but withoutmuch, if any, granular or finely divided material such as will notproduce the desired result. In typical cases lumps or sausages have beenused as small as one-quarter inch diameter, but three-sixteenths toone-half inch diameter by one-half inch up to, say, three inches lengthare preferable.

The lump mixture from the hopper is drawn into a pair of sheeting rolls3, 3, which elongate, flatten and consolidate the lumps to form acontinuous sheet 4, with correspondingly. elongated varicgations due tothe different colors and sizes of the lumps. The sheet thus formedpasses to a suitably driven conveyor 8, and is cut off in suitablelengths by means of a knife 9, mounted upon a cutter drum 6 incooperative relation with a roinvention; I will refer tary cutting bedor roll 7. The length of the severed sheets 10 will be predeterminedaecording to the width of the final sheet to be produced, such lengthbeing substantially the same or slightly greater than said width. Thedesired width of the final sheet having been determined, the size of thecutter drums or their speed of rotation will be governed accordingly. Ina particular case, the primary sheet may be, say, 36 inches in width,foldable to 18 inches, and the length may be, say, 76 inches.

The variegated sheets 10, being formed of lump material, have clearlydefined color areas, grained effect lengthwise in the direction ofrolling and elongation of the lumps. According to the preferred form ofmy invention, therefore, the sheets 10 are folded one or more times,preferably once, alongapproximately the longitudinal center line, as at11.- Obvionsly, the sequence of steps in the production of theindividual folded sheets may be somewhat varied, in that the primarycontinuous sheet 4 may be continuously folded, either by hand or bysheet-folding.

mechanism and v severed into the proper lengths after the folding. Thefolded sheets 16 are carried by the conveyor 8, to a position suitablefor transfer to chute 12, on which they are successively deposited intransversely overlapping relation, substantially as shown in Figs. 1 and3. The folded edge 15 of each sheet is preferably forwardly presented inthe chute and the overlap is such as to bring this forward edge inapproximate iregistry with the center line of the folded sheet which itoverlaps, so that the thickness of the pile at any point will not begreater than four times the thickness of the primary sheet. The foldedsheets'being placed in the proper overlapping relation, they arecontinuously fed down the inclined chute 1'3. to a second pair ofcalender rolls 13, 13'. Preferably, the thickness of the pile of ovenlapped folded sheets is not more than four to six times the thickness ofthe final sheet to be formed therefrom. These features ma v. however, bevaried as desired and will depend upon the relative thickness of theindividual and final sheets, and upon the number of folds, etc. In aspecial case. the thickness of the primary sheet may be inch. giv inginch thickness for the folded sheet and inch for the overlapped pilewhich may he rolled down to a final sheet, say, inch or more inthickness.

lVhile I have pointed out the advantages to be derived from folding ofindividual sheets. and the positionin of the folded edge of the sheetsoverlaying tiie preceding sheet in forming a continuous overlappingpile, nevertheless, it should be understood that it is within thepurview of my invention to utilize the individual sheet without folding.even but also have a pronounced striated or t the pass between the rolls13,13 as compared with the number of sheets and the total thickness ofthe sheets in the overlapped piles supplied to said roll. It is notessential that the widening of the pattern'by cross rolling be the sameas the elongation in the primary rolling,- but approximate e uality willbe found in most cases to give tie best simulation of natural marble.

' In the conventional calendering apparatus, the rolls are providedwith'axial passages. Throughone roll, steam or other heating fluid isusually circulated, while cold'water v is passed through the other. Thisoperates to maintain a small temperature differential between the tworolls, so that the plastic sheet because of its greater tendency toadhereto the cooler surface, will always follow and be carried by thewater cooled roll. Preferably, the'chute 12 extends over the warmer roll13,

in the form of an apron conforming to the curvature of the roll andterminating on a line 17, adjacent the nip of the rolls 1-3, 13. In thismanner, the individual overlapping sheetsare maintained out of contactwith the warmer roll 13, until they reach a point adjacent the nip ofthe rolls, Where they are engaged by the cooler or sheet carrying roll13, and consolidated into one continuous sheet 18. This method offeeding the overlapping variegated sheets to the final sheeting rollsavoids pulling or crowding ofthe sheets in the bite of the rolls, thusaiding in preventing the blending or clouding of the several colors. Thecontinuous sheet thus formed is stripped from the sheet carrying rollbythe doctor blade 14. It is to be noted that I have shown and describedthe relation of the overlapping folded sheets to be such that the foldedportion 15 will be in advance of .the body ofthe sheet and will befirstengagged by the nip of the rolls 13, 13'. These features of foldingand overlapping in the defined manner, are of importance in forming thedesired decorationand in )roducing a continuous sheet which is freesheets. Another feature is that the individual sheets 10, being ofuniform length predetermined .by the width of the final sheet, result inthe formation of a c ntinuous sheet of uniform width.

In some cases, as for example where the individual sheets 10 arerelatively soft because a relatively soft binding cement is rom mark- Iings indicating the junctions of the individual used in the linoleumcomposition, or because the sheeting rolls 13, 13are overheated (i. e.125 degrees to 17 5 degrees by the friction developed in a rapidsheeting operation, it

- vent the smearing of the colors. Accordingly, where there is atendency for the several colors in the individual folded sheets tobecome smeared or clouded in the final consolidating operation, Iprovide for positively controlling the temperature of the sheet carryingroll 13, whereby such roll is continuous y maintained at a temperaturesufficiently low to substantially prevent such smearing. In using theordinary linoleum mix, maintaining the. mix at a mean or averagetemperature of approximately 80 degrees F. or below during the finalconsolidating operation will be found satisfactory and, as beforestated, this may be accomplished by keeping the contact surface of thesheet carrying roll 13 at or below normal atmospheric temperature, thatis to say, at a mean or average temperature of degrees to 60 degreesFahrenheit or below. With linoleum compositions having-a softer cement,alower temperature will be required, while with relatively hardercement, a slightly higher temperature may be used. In general, 1t may besaid that the lower the temperature of the mix and of the sheet carryingroll 13, the more sharply defined will be the several color areas-in avariegated sheet, and the less the tendency to produce a grained orstriated formation.

While any desired expedients may be employed for controlling thetemperature of the sheet carrying ,roll 13' and for maintaining the saidroll at a relatively low predetermined temperature to prevent thesmearing or blending of the several colors, I have illustrated herein anapparatus which is specifically claimed-in my companion application Ser.

the cooling fluid, the amount of heat to be dissipated, and the ultimatetemperature which it is desired to maintain. Since a rapid transfer ofheat is desired, the jacket is preferably made of copper or other metalor substance having a relatively high co-efli the roll to cooling fluidin the jacket. Suitable openings 20, 21 are provided for the inlet andoutlet of the cooling fluid, such cooling fluid being water, brine, orany other well known refrigerating medium. As shown, the upper side ofthe jacket 19 is carried by the supporting frame by means of pins 23resting in the notches 24. Pivoted in this manner, the jacket restsfreely upon the roll 13, and by gravity induced frictional engagement,an efficient heat transferring relation is maintained. By this means thetemperature of the roll 13 may be positively-controlled throughout theprocess of consolidating the individual overlapping sheets, not only toprevent any excessive rise in temperature due to the heat developed inthe sheeting operation, but when desired to maintain the temperature ofthe roll below the predetermined maximum temperature to prevent smearingor blending of the several colors of the variegated sheet.

As stated above, the primary sheet 10 has a very definite and regularstriated or grained appearance while the final continuous sheet 18,obtained by my method of folding, overlapping and consolidating, issubstantially free from all grained or striated formation. Furthermore,the differently colored mate rials, while distributed in an irregularmanner, form sharply defined color areas in contrast to the blended orclouded effects produced from consolidating intimately mixed granularmaterial, for example.

The linoleum sheet 18 may be applied in continuous length to a suitablebacking, such as burlap, saturated felt or the like, in the usual mannerof producing linoleum floor coverings, or it may be employed with othersheets similarly variegated, or of solid color, to make block inlaidlinoleum in the wellknown automatic block inlaying machines of the\Valton or Batten type.

As will be apparent to those skilled in the art, this inventioncontributes an important advance in the linoleum industry in that itprovides for the first time a method and apparatus capable of producingby a continuous process of rolling, overlapping and cross-rolb i'ng, acontinuous sheet of indefinite length simulating the appearance ofnatural marble. In the teaching of method and apparatus for producingsuch a marbleized sheet of high ornamental quality and of suchcontinuity lengthwise that it can be used, for example, in the automatichigh speed inlaying ma chines of the lValton or Batten type, the presentinventor asserts his pioneership.

I claim:

1. A method of producing a continuous sheet of linoleum having marbleappearance, which consists in continuously forming sheets ofpredetermined length from lump linoleum composition of different colors,said sheets having a grained or striated effect in their longitudinaldirection, folding said sheets, laying the folded sheets in atransversely overlapping relation, and consolidating the overlappingsheets by cross rolling transversely of their length to produce acontinu' ous sheet.

2. A method of producing a continuous sheet of linoleum composition,having a variegated or marbled effect, which consists in mixing materialof different colors, rolling the material into sheets of lengthpredetermined by thewidth of the final sheet to be produced, foldingsaid sheets, the fold being longitudinal thereof, laying said foldedsheets in a transversely overlapping direction, and rolling saidoverlapping sheets in a direction at right angles to the first rolling,to produce a continuous sheet.

3. A method of producing a continuous sheet of linoleum compositionhaving a variegated or marbled effect, which consists in mixing lumpmaterial of different colors. rolling the lump material into sheets oflength predetermined by the width of the final sheet to be produced,folding said sheets, the fold being longitudinal thereof, laying saidfolded sheets in a transversely overlapping .direction, the foldedportion of each sheet being adjacent to the nest preceding folded sheet,and rolling said overlapping sheets in a direction at right angles tothe first rolling, to produce a continuous sheet.

4. A method of producing a continuous sheet of plastic material havingthe appearance of natural marble, which consists incontinuously formingsheets of predetermined length from lump plastic material ofdifferentcolors, said sheets'having a grained or striated formation in theirlongitudinal direction, folding said sheets, the fold being longitudinalthereof, laying the folded sheets in a transversely overlappingrelation, and consolidating the overlapping individual folded sheets byrolling transversely of their length to produce a continuous sheet.

5. A method of producing a continuous sheet of linoleum having marbleappeal-mice. which consists in continuously forming sheets ofpredetermined length from lump linoleum composition of different colors.said sheets having a grained or striated effect in their longitudinaldirection, folding said sheets, the fold being longitudinal thereof,laying the folded sheets in a transversely overlapping relation,consolidating the overlapping sheets by cross rolling transversely oftheir loo lflll length to produce a continuous sheet, and maintainingthe temperature of the sheet carryingroll below that temperature atwhich any substantial smearing or blending of the several colors willoccur.

6. A method of producing a continuous sheet of linoleum having marbleappearance,

which consists in continuously forming sheets of predetermined lengthfrom lump linoleum composition of different colors, said sheets having agrained or striated effect in their longitudinal direction, folding saidsheets, the fold being longitudinal thereof, laying the folded sheets ina transversely overlapping.

temperature at which any substantial smearing or blending of the severalcolors will occur.

7. A method of producing a continuous sheet of plastic material, havingthe appearance of natural marble, which consists in continuously formingsheets of predetermined length from plastic material of differentcolors,said sheets having'a grained or striated formation in theirlongitudinal direction, folding said sheets, the fold being longitudinalthereof, layng the folded sheets in a transversely overlapping relation,consolidating'the overlapping individual folded sheets by rollingtransversely of their length to produce a continuous sheet, andmaintaining the temperature of the sheet carrying roll below'thattemperature at which any substantial smearing 'or blending of theseveral colors will occur.

8. A method of producing. a continuous sheet of-linoleum composition,having a variegated or marbled effect, which consists in mixing materialof different colors, rolling the material into sheets of lengthpredetermined b the width of the final sheet to be produce folding saidsheets, the fold being longitudinal thereof, laying said folded sheetsin a transversely overlapping direction, rolling said overlappingsheets, in a direction at right angles to the first-rolling, to producea continuous sheet, and maintaining the temperature of the sheetcarrying roll at approximately atmospheric temperature throughoutthe'final consolidating operation.

9. A method of producing a ontinuous sheet of plastic material, havingthe appearance of natural marble, which consists in continuously formingsheets of predetermined length from lump plastic material of dlfi'erentcolors, said sheets having a grained or striated formation in theirlongitudinal direction, folding said sheets, the fold being longitudinalthereof, laying the folded sheets in a transversely overlappingrelation,

consolidating the overlapping individual folded sheets by rollingtransversely oftheir length to produce a continuous s maintaining thetemperature of the sheet carrying roll at approximately atmospherictemperature throughout the final consolidating operation.

10. A method of producing a continuous sheet of linoleum having theappearance of natural inarble, which includes rolling lump linoleumcomposition of different colors into sheets of predetermined length, thepattern formed by the lumps being lengthened longitudinally of the sheetso that the pattern widths in the sheet are much less than in thedesired natural marble pattern; overlapping the sheets laterallymaintaining a continuous supply of transversely overlapped thickness-'es thereof, and cross rolling the overlapped sheets transversely oftheir length to produce a continuous sheet and widen the pattern atright angles to the original elongation to the extent required toproduce the natural marble appearance. l

11. A method of producing a continuous sheet of linoleum having theappearance of natural marble, which includes rolling lump linoleumcomposition of different colors into primary sheets of predeterminedlengths, the pattern formed by the lumps being lengthened lon'tudinallyof the sheet so that the pattern widths in the sheet are muchless than in the desired natural marble pattern; overlapping the primarysheets laterally; maintaining a continuous supply of transverselyoverlapped primary sheets; consolidating and. cross rolling theoverlapped sheets transversely of their length to produce a continuoussheet and to widen the pattern at right angles to the originalelongation to the extent required to produce a natural marbleappearance; and refrigerating the sheet carrying roll to prevent thetemperature of its peripheral surface from increasing substantiallyabove atmospheric temperature during the consolidation of the overlapping primary'sheets.

12. In a machine for making inlaid linoleum or the like, in combination,a source of supply of plastic material, a pair of primary sheeting rollssupplied thereby and adapted to form a continuous sheet from saidplastic material, conveyor means in receiving relation to said pair ofprimary sheeting rolls, means for severing said continuous sheet intoindividual sheets of predetermined length, a support on which theindividual sheets may be piled in transversely overlap ping relation, asecond pair of sheeting rolls in receiving cross-rollmg relation to saidoverlapped sheets, and means for refrigerateet, and

ing the periphery of one of said second pair of sheeting rolls.

13. In a machine for making inlaid linoleum or the like, in combination,a source of supply of plastic material, a pair of primary sheeting rollssupplied thereby and adapted to form a continuous sheet from saidplastic material, conveyor means in receiving relation to said pair ofprimary sheeting rolls, means for severing said continuous sheet intoindividual sheets of predetermined length, a support on which theindividual sheets may be piled in transversely overlapping relation anda second pair of sheeting rolls in receiving cross rolling relation tosaid overlapped sheets.

14. A method of producing sheet material having the appearance oi":natural marble by a continuous process resulting in a sheet ofindefinite length and of generally uniform decorative effect from end toend which is characterized by mixing lump plastic material of differentcolors to provide a continuous supply of the mixture havingsubstantially homogeneous color composition; continuously forming saidmixture into sheet material having longitudinal color striations;overlapping said sheet material to produce a succession of layersforming a laminated sheet of a thickness substantially greater than thatintended "for the finished product and of continuous indefinite lengthin a direction transverse to said color striations; and then rolling thelaminated sheet transversely of said longitudinal striations to modifythe striations and produce a continuous consolidated sheet of reducedthickness.

15. In a machine for making sheet material or the like, in combination,means to supply a substantially continuous mixture of lump plasticmaterial of ditl'erent colors; a pair of primary sheeting rolls. inoperative relation to said supply means to receive said mixture of lumpplastic material and form it continuously into sheet material; conveyermeans in receiving relation to said primary sheeting rolls to receivesaid continuously formed sheet material and convey it toward asupporting means next recited; a supportmg means constructed to receivesaid sheet material in over-lapping relation to provide a secondarysupply of laminated sheet material of a thickness substantially greaterthan that intended for the finished product and a second pair ofsheeting rolls arranged to receive the laminated sheet materialcontinuously from said secondary supply and to roll it in a directiontransverse to the rolling by the primary sheeting rolls to produce'asheet of continuous indefinite length.

Signed at New York city in the county of New York and State of New Yorkthis 21st day of June, A. D. 192?.

MERLE. S. idoCONOUGHEY.

